Casingless food production methods, systems, and associated wrappable coverings

ABSTRACT

Systems, methods, and associated devices for casingless production of food products include: (a) moving at least one flexible cover member having a predetermined length with primary surface and opposing lateral edge portions along a predetermined travel path; (b) introducing a flowable food emulsion onto the primary surface of the flexible cover member; (c) wrapping the at least one flexible cover member about the food emulsion during the moving step; (d) advancing the wrapped emulsion into at least one forming tube having sufficient structural rigidity to be substantially non-deformable and having a preformed internal cavity space of predetermined size and shape; and (e) exposing the wrapped emulsion to predetermined processing conditions that convert the flowable emulsion to a non-flowable food product having substantially the molded shape of the forming tube as the wrapped emulsion advances through the at least one forming tube.

RELATED APPLICATIONS

This application is a divisional of U.S. patent Ser. No. 10/232,139,filed Aug. 30, 2002, the contents of which are hereby incorporated byreference as if recited in full herein.

FIELD OF THE INVENTION

The present invention relates to the casingless production of foodproduct.

BACKGROUND OF THE INVENTION

Conventionally, natural or artificial casings can be used to form andhold food products to help hold the shape and/or retain contentintegrity during processing, such as cooking, heating, or freezing. Thefood product can start as a flowable emulsion that can be stuffed intothe casing or the casing can be formed around the emulsion by employinga co-extrusion process using a stuffer, extruder, or the like. Thecasing itself may be disposable and removed from the food product priorto shipping and/or eating or may remain intact on the food productduring consumption and ingested.

Known extruders and co-extruders are available from various commercialmanufacturers including, but not limited to, the Kontura from TownsendEngineering Co., located in Des Moines, Iowa. Stuffers are availablefrom various commercial manufacturers including, but not limited to,HITEC Food Equipment, Inc., located in Elk Grove Village, Ill., TownsendEngineering Co., located in Des Moines, Iowa, Robert Reiser & Co., Inc.,located in Canton, Mass., and Handtmann, Inc., located in Buffalo Grove,Ill. Exemplary stuffer and/or linker apparatus are also described inU.S. Pat. Nos. 5,788,563; 5,480,346; 5,049,108; and 4,766,645. Thecontents of these patents are hereby incorporated by reference as ifrecited in full herein.

However, there remains a need to provide cost-effective automatedcasingless processing systems of food items.

SUMMARY OF THE INVENTION

The present invention provides casingless food production systems andmethods. The term “casingless” means that the food product can beproduced without requiring the assistance of a holding skin such as acollagen or natural skin casing. The term encompasses food items thatare conventionally produced using casings (such as hot dogs and sausagesand the like), as well as food items that have not required the use ofcasings (meatballs, popsicles, baked goods, shaped burgers, and thelike).

In certain embodiments, the methods and systems are configured toprovide casingless lengths of food product using endless wrappablecoverings that meet to encase the flowable food product therein. Thefood product can be configured to enter the wrappable covering as aflowable emulsion that is held encased in the covering as the coveringprogresses through a molding tube along a predetermined travel path.

In operation, as the product moves forward in the covering, the productis exposed to predetermined processing conditions that alter thephysical form of the emulsion to a non-flowable state. The change in thephysical state can be chemically or thermally initiated. Over time, theproduct can take on the shape of the molding tube with sufficientstructural rigidity so that it is able to retain that shape withoutsubstantial deformation after its release therefrom. As such, in certainembodiments, the released food item may be compressible (semi-solid andyielding to tactile compression forces) or substantially incompressible(frozen or solid) at ambient conditions.

The food may be elongated and regularly shaped (in an elongated orsubstantially cylindrically configuration) or may be non-elongated andirregularly shaped. The food may be cooked, frozen, smoked, cured,pickled, partially dehydrated, or otherwise processed as it movesthrough the processing region.

Certain embodiments are directed to methods producing food products thatinclude: (a) moving at least one flexible cover member having apredetermined length with primary surface and opposing lateral edgeportions along a predetermined travel path; (b) introducing a flowablefood emulsion onto the primary surface of the flexible cover member; (c)wrapping the at least one flexible cover member about the food emulsionduring the moving step; (d) advancing the wrapped emulsion into at leastone forming tube having sufficient structural rigidity to besubstantially non-deformable and having a preformed internal cavityspace of predetermined size and shape; and (e) exposing the wrappedemulsion to predetermined processing conditions that convert theflowable emulsion to a non-flowable food product having substantiallythe molded shape of the forming tube as the wrapped emulsion advancesthrough the at least one forming tube.

The at least one flexible cover member can be a single cover memberhaving a width that is sufficient to define a perimeter with theopposing lateral edges positioned proximate to each other and aninternal cavity gap space. The flexible member can have a substantiallyplanar configuration during a major portion of the predetermined travelpath. The wrapping operation can be carried out to cause the flexiblemember to take on a substantially cylindrical shape by moving theopposing lateral edge portions upward and inward so that the lateraledge portions reside proximate to each other.

Other embodiments are directed toward food production systems. Thesystems include: (a) at least one flexible wrappable member havingopposing first and second lateral edges and a primary surface, theflexible wrappable member arranged to extend axially in a predeterminedendless travel path, wherein, in operation, the first and second lateraledges are configured such that, in operation, they have a first spacedapart configuration and a second configuration with the lateral edgespositioned closer to one another in the second configuration, andwherein, when in the second configuration, the at least one flexiblewrappable member defines a perimeter with an internal cavity gap space;(b) at least one forming tube having sufficient structural rigidity todefine a preformed cavity space with a predetermined configuration, theat least one forming tube having opposing ingress and egress portions;(c) a flowable food emulsion source that is configured to introduceemulsion onto the wrappable member proximate to the at least one formingtube so that the emulsion resides in the internal cavity space of thesecond configuration; (d) a transport system that is configured to movethe wrappable member so that the wrappable member substantiallycontinuously travels, in serial order, to a first location that is influid communication with the food emulsion source, through said at leastone forming tube, and then back to the first location; and (e) aprocessing region having a thermal energy source operably associatedwith the predetermined travel path so that, in operation, the processingregion exposes emulsion in the wrappable member in the forming tube to apredetermined thermal processing condition as the wrappable membertravels along a portion of the endless travel path to convert theemulsion held in the at least one forming tube to a non-flowable foodproduct having substantially the molded shape of the forming tubecavity.

In certain embodiments, the system can include wrapping means disposedupstream of the at least one forming tube, the wrapping means configuredto wrap the wrappable member into a desired configuration.

The second configuration perimeter can be a closed perimeter thatencases the internal cavity space and holds the flowable emulsiontherein downstream of the first location and in the forming tube. In thesecond configuration, one of the respective lateral edge portions canoverlap the other. In other embodiments, in the second configuration,the lateral edges abut to define a seam region.

Other embodiments are directed toward apparatus for producing foodproducts. The apparatus includes: (a) means for moving at least oneflexible cover member having a predetermined length with primary surfaceand opposing lateral edge portions along a predetermined travel path;(b) means for introducing a flowable food emulsion onto the primarysurface of the flexible cover member; (c) means for wrapping the atleast one flexible cover member about the food emulsion during themoving step; (d) means for providing at least one forming tube havingsufficient structural rigidity to be substantially non-deformable andhaving a preformed internal cavity space of predetermined size andshape; and (e) means for exposing the wrapped emulsion to predeterminedprocessing conditions that convert the flowable emulsion to anon-flowable food product having substantially the molded shape of theforming tube as the wrapped emulsion advances through the at least oneforming tube.

These and other objects and aspects of the present invention areexplained in detail in the specification set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of a casingless foodstuff productionsystem employing wrappable surface coverings according to embodiments ofthe present invention.

FIG. 2A is a schematic side view of a wrappable surface covering havinga predetermined endless travel path according to embodiments of thepresent invention.

FIG. 2B is a schematic side perspective view of a casingless productionsystem with a forming tube, the wrappable surface covering thereofconfigured to travel therethrough in its travel path according toadditional embodiments of the present invention.

FIG. 3A is a partial schematic view of a wrappable covering shown in awrapped (overlapping) configuration according to embodiments of thepresent invention.

FIG. 3B is a partial view of a portion of the wrappable covering of FIG.3A, shown in an open or unwrapped configuration according to embodimentsof the present invention.

FIG. 3C is a partial side perspective view of a processed food productthat is shaped and includes surface indicia corresponding to that on thewrappable covering shown in FIGS. 3A and 3B.

FIGS. 4A-4C are schematic illustrations of examples of alterations inthe physical state or consistency of the emulsion held in the wrappablecovering as it travels along the food travel path and is exposed toselected thermal processing conditions according to embodiments of thepresent invention.

FIG. 5 is a schematic illustration of an alteration in the physicalstate or consistency of the emulsion held in the wrappable covering asit travels along the food travel path and is exposed to selected coolingprocessing conditions according to embodiments of the present inventionillustrating that a cooling source may be used in the processing regionto facilitate the molding or alteration of the flowable emulsion to anon-flowable molded shape.

FIG. 6A illustrates three different exemplary processing conditionsalong a food travel path according to embodiments of the presentinvention.

FIGS. 6B-6E are graphs of profiles of processing temperature as afunction of time for the system of FIG. 6A according to embodiments ofthe present invention.

FIG. 7A is a schematic illustration of a processing system that includesa plurality of forming tubes of production lines according toembodiments of the present invention.

FIG. 7B is an enlarged end view of one exemplary arrangement of theplurality of forming tubes in the system shown in FIG. 7A.

FIG. 7C is a schematic illustration of a processing system similar tothat shown in FIG. 7A, but showing vertical food forming paths accordingto embodiments of the present invention.

FIG. 8A is a schematic illustration of a processing system that includesa plurality of forming tubes in fluid communication with respectiveemulsion filled hoppers according to embodiments of the presentinvention.

FIG. 8B is a schematic illustration of a processing system that includesa plurality of forming tubes and a plurality of sub-hoppers fed by aprimary hopper according to alternative embodiments of the presentinvention.

FIG. 8C is a schematic illustration of a processing system that includesa plurality of forming tubes and a primary hopper and distributionmanifold according to alternative embodiments of the present invention.

FIGS. 9A and 9B are front section views of forming tubes configured toprovide non-customary cross-sectional profiles of food productsaccording to embodiments of the present invention.

FIG. 10A is a schematic perspective side view of a processing systememploying multiple wrappable surface coverings that meet in a formingtube to encase the product according to certain embodiments of thepresent invention.

FIG. 10B is a front view of the forming tube and wrappable surfacecoverings shown in FIG. 10A.

FIG. 10C is a front view of the forming tube and wrappable surfacecoverings shown in FIG. 10B with the coverings expanded outwardlyresponsive to pressure generated by the emulsion held therein accordingto certain embodiments of the present invention.

FIG. 10D is a partial front perspective view of a wrappable surfacecover member that illustrates that the food contacting surface coveringcan be configured with a concave face according to embodiments of thepresent invention.

FIG. 11A is a schematic illustration of a dual line processing systemaccording to embodiments of the present invention.

FIG. 11B is a schematic illustration of an alternate dual lineprocessing system.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying figures, in which embodiments of theinvention are shown. This invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein. Like numbers refer to like elementsthroughout. In the figures, certain layers, components or features maybe exaggerated for clarity, and broken lines illustrate optionalfeatures or operations unless specified otherwise. In addition, thesequence of operations (or steps) is not limited to the order presentedin the claims unless specifically indicated otherwise.

In the description of the present invention that follows, certain termsare employed to refer to the positional relationship of certainstructures relative to other structures. As used herein, the term“forward” and derivatives thereof refer to the general or primarydirection that food travels as it moves inside a food processor from aprocessing point or region to the next processing point or region; thisterm is intended to be synonymous with the term “downstream,” which isoften used in manufacturing environments to indicate that certainmaterial being acted upon is farther along in the manufacturing processthan other material. Conversely, the terms “rearward” and “upstream” andderivatives thereof refer to the directions opposite, respectively, theforward and downstream directions.

The present invention may be particularly suitable to produce food itemssuch as, but not limited to, elastic or partially elastic food itemssuch as meat products, cheese (e.g., mozzarella strands), or dough. Incertain embodiments, the food products are whole or partial meatmixtures that include a single or multiple different types of meatincluding, but not limited to, beef, poultry, lamb, veal, and porkincluding derivatives and/or meat analogs of selected ones orcombinations of the meat. Other animal, poultry, fish, or desired meatsmay also be employed where desired. The meat based food products may bemeat sticks or strands, elongate meat products such as hot dogs,sausages (of any type including Vienna sausage (typically a beef, pork,and veal emulsion blend)), and the like. In other embodiments, the foodproducts need not be elongate and can be candy and/or frozen dessertsnack treats such as ice cream, yogurt, popsicles, and the like.

Generally described, in certain embodiments, the product is produced byintroducing (typically injecting) under pressure a flowable foodmaterial(s) onto a wrappable surface covering. The wrappable surfacecovering may be wrapped into a closed perimeter configuration or can bepartially or wholly open when the food emulsion or flowable foodmaterial is introduced thereon. The wrappable surface covering cansubstantially wrap around the food (such that edges meet or overlap) toencase the emulsion material. The wrappable surface covering, whenwrapped into a desired configuration that holds the food emulsion, canbe directed to move through a molding or forming tube. The terms“forming” and “molding” tube are used interchangeably herein.

The flowable material can be configured as an emulsion or slurry of asingle “primary” and/or “major” constituent and a liquid (such as wateror other food compatible liquid) or an emulsion or slurry mixture ofseveral different major constituents. “Primary” and/or “major” as usedherein means that that constituent is present as at least 10% of thevolume of the emulsion or slurry. As the wrappable covering with theencased food material travels forward along its selected travel path,the encased material alters to a non-flowable state and takes on theshape defined by the cavity of the wrappable covering and/or tube. Incertain embodiments, the product is exposed to predetermined processingconditions that alter the physical form of a flowable emulsion to anon-flowable state. The processing conditions can include one or more ofthermal energy (hot or cold), microwave energy, RF energy, UV light,laser energy, and the like.

In certain embodiments, the change in the physical state can bechemically or thermally initiated. In particular embodiments, certain ofthe constituent ingredients may be chosen so that when combined andexposed to a predetermined activation condition, such as heat, theyreact to yield a desired change in the physical state or a desiredchange in the food value. Over time, the chemical or thermal initiatedreaction can cause the product to harden or become more viscous andnon-flowable and form substantially into the shape of the wrappedcovering and/or tube. Upon release, the product has the shape of thewrapped covering and/or tube, modified with surface textures or indiciaprovided by the surface wrapping. As such, in certain embodiments, thereleased food item may be compressible (semi-solid and yielding totactile compression forces) or substantially incompressible (frozen orsolid) at ambient conditions. The forming tube or mold itself isconfigured with sufficient structural rigidity so that it is able todefine a mold cavity without the emulsion held therein and to resistdeformation when the emulsion and covering are introduced into thecavity of the forming tube under pressure sufficient in magnitude tocause the product to contact and expand the surface covering tosubstantially fill and/or take the form of the forming or molding tubecavity.

In certain embodiments, the flowable emulsion may be a meat productemulsion that can include additives, flavorings, vegetables, fruits,spices, or other edible biocompatible constituents. Some constituents ofthe flowable emulsion may include fluids, such as liquids, solidparticulates of various sizes, and ground, shredded, segmented orotherwise processed meat, meat analogs, or derivatives thereof. Incertain embodiments, the emulsion can be viscous, while in others it maybe semi-viscous and/or substantially inviscid at the initiation of theprocess (such as at introduction into the covering). Thus, the systemscontemplated by the present invention may be used to process foodproducts in a wide variety of density ranges (low to high), such aswater (to ice), fluffed creams, meat or meat analog slurries, and thelike.

The emulsion can be selected to yield elongated food items including,but not limited to, hot dogs, sausages, and the like. The end item maybe elastic so as to allow some stretching without unduly altering ordeforming its desired shape (from that of the mold shape) after releasefrom the forming tube and/or the wrappable surface covering duringprocessing. Alternatively, the emulsion, forming tube, and wrappablecoverings may be formulated so that discrete non-elongated products suchas shaped meatballs and other food products may be produced.

In particular embodiments, after the product exits the forming tube oras it travels in the forming tube encased by the wrappable covering, theproduct can be coated with a desired edible surface coating, such as,but not limited to, sugar, chocolate, candy sprinkles, and the like forsweet or dessert products or corn meal for corndogs, flour or otheredible coating for other food products. The coating may be aerosolized,sprayed, pressed or otherwise deposited onto all or selected exteriorsurfaces of the product.

Turning now to FIG. 1, one embodiment of a casingless food productionsystem 10 is shown. As shown, the system 10 includes a travelingwrappable covering member 5, a forming or molding tube 15, a thermalsource in a processing region 20, and a flowable foodstuff supply source50S. In the embodiment shown in FIGS. 1 and 2A-2B, the wrappablecovering member 5 is a resilient member defined by single flexibleendless conveyor belt 5 f that has a width (“W”, FIG. 2B) sized so that,in operation, opposing side edges 5 e ₁, 5 e ₂ can be wrapped to meetand/or overlap to define a cavity space. The width of the wrappablemember 5 and the cross-sectional shape of the forming tube 15 helpdefine the volume, shape, and/or size of the cavity space. The amountand density of the emulsion 30 e, as well as the selection of materialthat forms the wrappable member 5 and the tension thereof, can alsoinfluence the size and shape of the cavity space 5 c as the wrappablemember 5 can, in certain embodiments, flex outwardly in the direction ofthe forming tube 15 as the emulsion 30 e fills the cavity space 5 c andforces the flexible wrappable member 5 outward.

Alternatively, the wrappable member 5 can be a plurality of members thatare directed to meet to encase the emulsion 30 e. For example, as shownin FIG. 10B, the wrappable member(s) 5 (shown as three members 5 ₁, 5 ₂,5 ₃, in this embodiment) have a first substantially non-outwardly flexedconfiguration in the absence of emulsion. FIG. 10C then illustrates asecond outwardly flexed configuration when filled with emulsion forcingthe wrappable member(s) 5 to contact and substantially take on the shapeof the forming tube 15. FIG. 10D is a partial view of a wrappablesurface covering 5 that illustrates that the covering can be pre-formedto have a concave face according to embodiments of the presentinvention. This configuration can be used as a single wrappable coveringmember 5 or as one of the plurality, each of the plurality or selectedones may be preformed into a concave configuration.

The wrappable cover member 5 may be configured as any suitable foodcompatible flexible or wrappable material, such as, but not limited to,cloth (which may be woven), paper, elastomer, polymer, metallic or othermesh material, and combinations thereof. The cover member 5 may be athin (less than about 0.5 inches, typically less than about 0.10 inches)flexible member.

Referring back to FIG. 2B, the wrappable member 5 is disposedintermediate the emulsion 30 e and/or product 30 p and the forming tube15. FIG. 1 illustrates exemplary changes in the density or structure ofthe product 30 p as it moves through the processing station 20 (shown asa thermal station with a heat source). The circular shapes labeled as“A”, “B”, and “C” illustrate an exemplary alteration in density orflowability of the food as it travels along the food travel path. Atlocation “A”, the product is a flowable emulsion, at location “B” somephysical alteration has occurred (illustrated as a thicker density atthe outermost portions of the food), and at location “C” the food hasbeen processed so that it is of a substantially constant consistencythrough its center (e.g., cooked). The exemplary condition of the foodat location “B” can vary depending on the production exposureenvironments or thermal processing conditions. For example, RF ormicrowave thermal processing or combinations of processingenvironments/exposures may result in a different food density gradients.Other alteration patterns may occur depending on the desired processingresult, the type of processing employed, the thickness of the tubeand/or covering and the food being processed.

In the embodiment shown in FIG. 1, the wrappable covering 5 has anendless travel path and is configured to automatically repeatedly travelabout that travel path. The system 10 also includes a transport or drivesystem 11 (FIG. 2A) that moves the wrappable covering member 5 along itspredetermined travel path. The transport system 11 can compriseconveyors, belts, chains, cables, cords, or other drive means connectedto a drive motor to move the wrappable member 5 and direct the wrappablemember 5 to come together at predetermined portions of the travel path.The speed that the wrappable member 5 moves along its endless path canbe selected so that the food is exposed to the desired food processingconditions for the desired time.

In operation, for the embodiment shown in FIGS. 1, 2A and 2B, thewrappable covering member 5 travels about its predetermined travel path15 p. As the wrappable covering member 5 approaches the emulsion source50 s, the opposing lateral edge portions 5 e ₁, 5 e ₂ are wrapped ordirected up and toward each other so that the wrappable member 5 closesabout itself to define the outer perimeter of an enclosed cavity space 5c. The lateral edge portions 5 e ₁, 5 e ₂, may meet about a seam region5 r (FIG. 2B) that is substantially flush with the opposing edges.Alternatively, the seam region 5 r may be formed by holding one edgeportion under the other so that there is an overlap in the seam region 5r. The wrappable member 5 may be forced by positioning forming membersin the travel path to cause the wrappable member 5 to wrap into adesired configuration. Although shown as being wrapped upwardly, theside edges can also be wrapped downwardly so that the seam region is onthe bottom. In other embodiments, the wrappable member 5 can be orientedso that the opposing edges are wrapped together to meet at a sidelocation, rather than a top or bottom location (not shown).

In certain embodiments, as shown in FIG. 2B, forming fingers 21 f can beplaced in the covering 5 travel path so that the opposing lateral edgeportions 5 e ₁, 5 e ₂ are forced inwardly as the wrappable member 5moves forward and approaches the forming tube 15. The forming fingers 21f may float or be configured to rise vertically to force the edgeportions upward and inward. A series of forming fingers 21 f can bepositioned to incrementally force the wrapping operation to occur alongthe travel path in advance of the forming tube 15 (not shown). Theforming tube 15 itself may be configured and sized to facilitate thewrapping and/or to force the closing or meeting of the edge portions 5 e₁, 5 e ₂. Similarly, a series of differently sized or shaped formingtubes 15 or forming mandrels (such as with decrementing sized interiorspaces and/or rising sides) may be spaced apart about the travel path tocause the wrappable member to wrap about the cavity space. The formingtube 15 may use a spool or mandrel to facilitate the forming of thecavity space 5 c prior to or upstream of the emulsion introductionlocation (not shown).

In other embodiments, instead of and/or with the forming fingers 21 f, achannel of upwardly extending side portions can be positioned along thetravel path 15. The channel can have a width that decreases as itapproaches the forming tube 15. In operation, the decreasing width andupwardly extending side portions can be used to direct the sides of thewrappable member to curve or rise upward to meet at the forming tube 15(also not shown). Other forming or wrapping operations and devices mayalso be used as is known to those of skill in the art.

In any event, the wrapped member 5 then enters the forming tube 15 andmoves through the length of forming tube 15. The emulsion 30 e can beintroduced onto the wrappable member 5 in advance of the forming tube15, prior to the wrapping member forming the cavity space 5 c or afteror proximate to the forming tube 15 when the cavity space is set. Theemulsion 30 e can be flowably pumped and/or injected into the tubeand/or onto the exposed primary surface of the wrappable member 5. Asthe emulsion travels through the tube 15, it can be exposed to desiredprocessing conditions. In the embodiment shown in FIGS. 1 and 2B, theemulsion 30 e is exposed to thermal processing conditions causing it tochange its density or physical condition or structure. At the end of theforming tube 15, the wrappable member 5 exits, and the opposing edgeportions 5 e ₁, 5 e ₂, separate to open (unwrap) the cavity space 5 c toexpose the product 30 p. That portion of the unwrapped member 5 thencontinues back or returns along its predetermined travel path 15 p tostart the process again. If the emulsion 30 e is continuouslyintroduced, a continuous strand or length of product can be produced orreleased at the end of the forming tube 15. Intermittent introductioncan provide shorter lengths.

FIG. 3A illustrates one example of a wrapped member 5 w that defines thecavity space 5 c. The wrapped member 5 w can be formed by a conveyorfloor. FIG. 3B illustrates an unwrapped configuration 5 u of the member5. FIGS. 3A and 3B also show that the wrappable member 5 can includesurface indicia 121 thereon. The surface indicia 121 can be configuredin a pattern corresponding to the surface pattern desired to betransferred or formed into the externally viewable surface of the moldedfood product 30 p (FIG. 3C). The surface indicia 121 can be formed adesired depth into the outer surface of the product 30 p, depending onthe configuration of the indicia on the wrappable covering member 5, theforce or amount of emulsion 30 e used to fill the forming tube andmember 5 cavity, and the formulation of the emulsion 30 e and/or product30 p itself. The surface indicia pattern 121 can be configured as arecessed female deformation pattern and/or as a raised male deformationpattern.

One or both opposing lateral sides of the primary surface (foodcontacting surface) of the wrappable member 5 can include the same,different, or cooperating complementary indicia that together define acontinuous pattern extending over the outer surface of the food.Different patterns can be used about different lengths of the wrappablemember to produce differently marked food items 30 p (not shown). Thedepth or projection distance of the surface indicia 121 can beconfigured to provide a sufficiently prominent transferred patternformed onto the exterior of the food product as the emulsion flows intothe cavity 5C and takes on the molded shape defined by the cavity 5Cand/or molding tube cavity as the food 30 e is moved along thepredetermined travel path 15 p in the food processing system 10. Incertain embodiments, the surface indicia 121 can comprise alphanumericindicia. In particular embodiments, the surface indicia can include adesign shape, decorative pattern, or figure, such as a product orcompany logo, mark, and the like. In other embodiments, the innersurface of the member 5 can be configured to impart a desired surfacemarking or texture, such as representing seared grill marks,predetermined visually darker regions, and the like. In particularembodiments, the surface indicia 121 can be provided by recessed wells(female deformations) that can hold a dye to allow for selective colorapplication.

The processing region 20 can include different processing environments.By way of illustration, as shown in FIG. 6A, the system 10 can include aplurality of processing regions. As shown in FIG. 6A, it includes threedifferent processing regions 20A (shown as a heating zone), 20B (shownas a thermal holding zone), and 20C (shown as a second thermal zone,which may be a cooling zone), each of which can present a differentenvironment for the food. The emulsion and/or food 30 e/30 p can travelencased in the wrappable covering member 5 throughout each processingregion 20A, 20B, 20C or can be released from the wrapped covering 5 w(FIG. 3A) at a desired region and processed independent of the tube 15and/or covering member 5 after traveling through a selected portion ofthe processing system 10 (such as after traveling through major portionof one region 20A or two regions 20A, 20B (FIG. 6A).

In certain embodiments, as shown in FIG. 1, the supply source 50Scomprises an injection nozzle 50N that is configured and positioned tobe in fluid communication with the rearward portion of the forming tube15. The nozzle 50N can be operated to substantially continuously, or atdesired intervals, introduce the emulsion into the wrappable member andforming tube 15. The nozzle 50N may be held stationary in the travelpath of the wrappable member upstream or proximate the tube 15.Alternatively, the nozzle 50N may be dynamically operated, such asinserted into and retracted from the forming tube 15 and/or wrappablemember 5. The speed of forward movement of the wrappable member as wellas the flow rate of the emulsion can be selected to inhibit the undueloss of product through rearward flow or exit through the seam region.

In certain embodiments, the tube 15 and/or the wrappable member 5 can bepreheated or pre-cooled prior to the introduction of the emulsiontherein to cause the outermost portion of the emulsion to gel relativelyquickly in the cavity 5 c, thereby inhibiting excessive spill, flashing,or leakage from the cavity or member 5.

The wrappable member 5 can be directed to travel through a sterilizationregion after it opens or unwraps and before it returns to accept anotherquantity of emulsion. The exposure can be for a period of time to allowcleansing or sterilization of the food contacting surfaces. Thesterilization region can be located along a portion of the travel pathand periodically activated (or continuously activated). Thus, thesterilization or cleansing may be carried out automatically by directingthe travel path to extend through such a processing region.

In certain embodiments, the travel path can be sized and configured toproduce two products per cycle (not shown). That is, the system 10 caninclude a second filling station that is located downstream of the firstsupply station. The wrappable member 5 can be directed to close or wrapagain and directed to travel through a separate second forming tube alsodownstream of the first forming tube 15. Thus, the wrappable member 5can meet to close, enter a forming tube 15, and open twice along asingle cycle of its travel in the travel path 15P.

It is noted that the wrappable member 5 and/or the forming tube 15 canbe formed of a food-compatible material. In addition, suitablefood-compatible coatings or lubricants may also be deposited onto theinner surfaces of the cavities (the inner surface of the forming tubeand/or the inner surface of the wrapped member 5 w ) as well as theouter primary surface of the member 5 to inhibit contact adherence,promote movement, and/or promote ease of removal. Such coatings may beintegral to the cavity material, or applied at desired intervals from anexogenous source.

FIGS. 4A, 4B and 4C illustrate that the product 30 p can be processed indifferent manners, each of which may generate a different distributionpattern of the emulsion to the formed product. FIGS. 4A-4C eachillustrate a processing region or thermal zone over the length of whichthe emulsion 30 e undergoes the heating and molding into a structurallysuitable shaped (non-flowable) product 30 p. FIG. 5 illustrates asimilar variation using a cooling source to produce the molded product30 p. The darker shades rendered in the graduated shading shown in FIGS.4A, 4B, 4C and 5 illustrate cooked, frozen, or increased densityalterations in the emulsion 30 e from its original flowable state.

As discussed above, the processing region 20 can include one or aplurality of different treatment zones or environments. In applicationsthat cook or heat the product 30 p, the cooking, heating and/or coolingcan be carried out by any suitable energy generating means as discussedabove, including, but not limited to, microwave, RF, UV light, laserenergy, thermal energy (heating in a conventional convection orconduction oven or cooling of freezing in refrigerators/freezers),radiation energy, and the like, as well as combinations of same. Assuch, as the emulsion 30 e travels through the processing region 20,along the predetermined travel path, it can be heated for predeterminedtimes and temperatures.

In certain embodiments, as shown in FIG. 6A, the processing region 20comprises three different treatment zones: (a) an active or distributedenergy generating zone 20A that is used to expose the food emulsion to adesired thermal energy at a desired time versus temperature profile; (b)a thermal (equilibrium) holding zone 20B where the temperature of theproduct is held substantially constant; and (c) a thermal zone 20C,which may be a cooling zone where the temperature of the product isreduced. FIGS. 6B-6E illustrate examples of different time versustemperature profiles of exemplary processing conditions corresponding tothe different processing regions. The temperature profile may correspondto a selected location in the product (such as a center region of theproduct to promote reliable cooking). Other temperature profiles,residence times, and the like can be used depending on the application.

FIG. 6B illustrates that the product temperature is returned to ambienttemperature and the thermal holding zone can hold the product at asubstantially constant internal temperature. FIG. 6C illustrates thatthe thermal processing may raise the internal temperature and then lowerthe product temperature to a cooled or frozen refrigerated temperature(the line extending below the initial condition). FIG. 6D alsoillustrates that the thermal holding zone can allow the product toincrease in temperature and then hold a substantially constanttemperature for a desired time. FIG. 6D illustrates that the holdingzone may decrease the internal temperature before the product enters thecooling zone. Where used, the cooling zone may be non-active ornon-force cooled (fans or natural air cooling can be used) to return theproduct to ambient.

FIG. 6E illustrates that the last thermal zone may be another heatingzone (top line) or a cooling zone (broken bottom line). Each thermalregion may increase (or decrease) the temperature and then hold thattemperature for a desired time. The top line indicates that the thermaltemperature is increased in the initial portion of each thermal zone.Other heating and cooling cycles or operations may also be used. Forexample, as shown in FIG. 6E, each thermal region can increase thetemperature of the product and include a thermal holding zone. As shown,the thermal processing can be carried out to provide three increasedramped slope portions, each ending in a more level horizontal “holding”temperature portion. The thermal processing can be carried out toinclude cooling or combinations of heating and cooling.

In particular embodiments, the thermal heating zone and/or the thermalholding zone are configured to raise the internal temperature of theemulsion to a desired temperature for a desired time. For example, incertain embodiments, the processing region 20 can be configured to raisethe internal temperature of the wrapped or unwrapped emulsion or product30 e/30 p so that it reaches at least about 150 degrees Fahrenheit for apredetermined time. In particular embodiments, for meat emulsions, theproduct may be cooked to an internal temperature of about 158 degreesFahrenheit.

In other embodiments, the product 30 p can be cooked and then frozen inpreparation for shipment. The product should be structurally sufficient(such as after cooking but before freezing) so that it can substantiallymaintain its molded shape when removed from the wrapped covering 5 wand/or forming tube 15. In yet other embodiments, the product 30 p canbe directly frozen without cooking (typically for food intended to beeaten in a frozen state).

In certain embodiments, the processing region 20 is configured to heatthe emulsion or product with one or more microwave energy generators togenerate about 400-600 kW of microwave energy in the thermaldistribution region to cook the emulsion in the shells for predeterminedtimes and energy levels as the emulsion travels enclosed in the shellsalong the predetermined travel path. For example, five 100 kW generatorsoperating at about 85% efficiency can generate about 425 kW of microwaveenergy that can be directed to a certain (typically shielded) portion ofthe processing region 20.

FIGS. 9A-9B illustrate that the forming or molding tube 15 can beconfigured with cavities 15 c to provide molded food product innon-conventional or irregular cross-sectional (and/or side sectional)shapes. FIG. 9A illustrates a block shape (such as square orrectangular). If molded with sufficient lengths of emulsion, thisconfiguration would produce a product 30 p shape that is similar to abar (not shown). FIG. 9B illustrates a football sectional shape that canbe produced in the axial direction. Thus, the forming tube 15configuration can be selected to provide a non-circular cross-sectionalproduct, a product with an irregular complex or non-constant shapecross-sectional profile, and/or an irregular side profile with anelongate but non-cylindrical shape.

The thickness and type of materials selected to form the forming tube 15as well as the wrappable member 5 may depend on the productionenvironments that the food will be exposed to as well as theconfiguration (type and size) of the food being processed. For example,light, microwave, thermal (heat and/or cooling), and RF energies mayhave different demands that promote uniform and reliable transfer of thetreatment to the food product and/or suitable exposures and exposurerates in an aesthetically acceptable manner. The forming tube 15 can beformed of stainless steel (such as 316 stainless steel) or otherfood-compatible material. In other embodiments, at least a portion ofthe forming tube 15 is formed of a non-metallic material. The innersurface of the forming tube 15 and the inner and/or outer primarysurfaces of the wrappable member 5 can be configured with a non-sticksurface and/or include lubrication. Examples of non-metallic materialtypes include, but are not limited to, resin or fiber reinforced resin,ceramic, polymer or co-polymer and blends and derivatives thereof orplastic material (such as polyvinylchloride “PVC”), silica (such asaluminosilicate or glass), or other suitable material having sufficientrigidity to withstand the operating pressures and heat. Suitablefood-compatible coatings, claddings, or lubricants may also be depositedonto the surfaces of the inner wall or surface of the forming tube moldcavity 15 c to inhibit contact adherence thereto. Such coatings orlubricants may be integral to the cavity material, or applied at desiredintervals from an exogeneous source. One suitable material and/orcoating is TEFLON® polymer.

In certain embodiments, the system 10 can include a portion (such as awindow or cylindrical ring) that is optically translucent or transparentto allow visualization or optical sensing of the state (intensity) ofthe emulsion 30 e and/or product 30 p as it travels therethrough. Anoptical encoder (not shown) can be used to provide an alert when imagedensity data is outside expected limits, thereby indicating a potentialproblem in the processing of the emulsion (such as over-or under-cookingor cooling or an emulsion composition irregularity).

In certain embodiments, as shown in FIG. 7A, the processing region 20may comprises a microwave oven 21 that is sized to process a pluralityof separate production lines (for clarity, the wrappable member 5 is notshown in FIGS. 7A-7C). As such, the forming tubes 15 can have anon-metallic 15N region along at least the length L₁ that corresponds toor is coextensive with the inner space of the microwave oven 21.

As discussed above, the processing region 20 can include one or aplurality of different treatment zones or environments. In applicationsthat cook or heat the product 30P, the cooking, heating and/or coolingcan be carried out by a selected one or combination of any suitableenergy generating means as discussed above, including, but not limitedto, microwave energy, RF energy, UV light, laser energy, thermal energy(heating in a conventional convection or conduction oven or cooling offreezing in refrigerators/freezers), radiation energy, and the like. Assuch, the emulsion 30 e travels through the tube 15 encased in thewrapped member 5 in the processing region 20, along a predeterminedtravel path, and can be heated (and/or cooled) for predetermined timesand temperatures.

FIG. 7A illustrates that a plurality of different spaced apart formingtubes 15 can be encased or directed to extend through a commonprocessing region 20. As shown, the processing region 20 includes anoven 21. The oven 21 is configured to enclose the plurality of formingtubes 15. The oven 21 can include one or a plurality of thermal sources(shown as five designated as 21A₁-21A₅ in FIG. 7A). Each can generatethermal energy for a respective forming tube 15, or for localizedregions in the oven, and/or to provide a substantially constant energyexposure across the oven so that the energy is distributed in apredetermined manner across the emulsion traveling in each of the tubes15.

FIG. 7A also illustrates that the temperature of the product can beraised from a first starting temperature T₁ to a second predeterminedcooked temperature T₂ In certain embodiments, the second temperature maybe at least about double the starting temperature (measured in degreesFahrenheit). In the embodiment shown in FIG. 7A, the temperature of theemulsion 30 e may be increased from about 50° F. (10° C.) to about 158°F. (70° C.) from the ingress portion of the oven 21 i to the egressportion of the oven 21 e.

In certain embodiments, the oven 21 is configured to heat the emulsion30 e with one or more microwave energy generators to generate about400-600 kW of microwave energy generated in the temperatures zone orthermal distribution region to cook the emulsion in the shells forpredetermined times and energy levels as the emulsion travels enclosedin the forming tube. The power generators 21A₁-21A₅ shown in FIG. 7A canbe five 100 kW generators operating at about 85% efficiency can generateabout 425 kW of microwave energy that can be directed to a certainportion of the processing region 20 (typically one shielded from theplant or adjacent processing regions).

In particular embodiments, the processing conditions can be set tointroduce a simulated skin layer onto the outer surface of the emulsionor product. The simulated skin can be formed before or after its releasefrom the covering member 5. That is, relatively hot or high-energyapplied to the outer perimeter of the emulsion 30 e or food product 30 pcan provide an increased density or drier region relative to the innerportion of the resultant non-flowable edible product. The depth orthickness, as well as the density or hardness of the skin layer, can beadjusted by the processing conditions. The wrapped member 5 itself maybe heated (or preheated) and/or the tube 15 may be heated (or preheated)to apply contact heat to the wrappable member 5 that is localized at theouter surface of the underlying food material to apply contact heat thatis localized at the outer surface. In other embodiments, RF or microwaveenergy and the like can be used.

FIG. 7B illustrates that each of the forming tubes 15 in the oven 21 canbe in the same configuration (size and shape). In other embodiments,different size and/or shaped forming tubes 15 (not shown) can be used.The forming tubes 15 can be formed with a selected cross-sectional areaand length (defining a known volume) and the rate of flow adjusted tothe volume so as to provide the desired pressure and/or allow thewrappable member 5 to travel therethrough to move the product forward.

As shown, the forming tubes 15 can have the same lengths and beconfigured to extend through substantially the entire length of the ovenspace associated with the processing region 20. In other embodiments, arespective production line may have a different length forming tube 15and the product or emulsion therein can be directed to exit the oven ata different egress portion (not shown). Each of the forming tubes 15 canbe associated with a respective production line, each capable ofconcurrently producing molded or non-flowable products 30 p. As such,the forming tube 15 for each production line can be configured so thatfood material and respective wrappable members 5 travel concurrentlythrough a common processing region (using a processing region configuredto surround a plurality of forming tubes for a plurality of productionlines, with a shared heating, holding and/or cooling region). Each linemay be operated to yield the same product in the same or differentshapes or sizes, or different products.

As shown in FIG. 7A, the system 10 may include a central controller 60that directs the operation of a plurality of different energy sources.The controller 60 can adjust the energy generated depending on the typeof product traveling in the processing region (such as the size (volume)of the forming tube and/or type of emulsion mixture in the wrappablemember 5 in the forming tube 15N). The controller 60 may also be used toadjust system pressure, pump rate, valves associated with the flow pathand emulsion supply source, and the like. The energy sources or powergenerators may be of the same type and operated to maintain a homogenousor constant energy or temperature region in the processing region.Alternatively, selected ones of the energy sources or power generatorsmay be operated to produce local “hot” or “cold” spots or graduatedheating or cooling treatment zones as desired.

FIG. 7A illustrates that the forming tubes 15 may be oriented above,below, and/or transversely spaced apart from the others and directed toflow in a substantially horizontal throughput configuration through theprocessing region 20. FIG. 7C illustrates a tube assembly configurationwith a plurality of spaced apart forming tubes 15 held in asubstantially vertical orientation. The tubes 15 (one or more) can beheld in a diagonal, sloped, curvilinear and or other configuration,arrangement and/or orientation (not shown).

In certain embodiments, the devices, systems, and methods of the presentinvention can be used to continually produce a series of lengths ofproduct that can be cut or separated into desired lengths, or which canbe ejected from the wrappable member 5 and/or forming tube 15 in asubstantially desired predetermined length of a discrete product.

The term “continually” means that the apparatus can be configured toexpel or provide a series of products substantially constantly over aproduction shift or batch. In certain embodiments, the systems 10 can beconfigured to process individual shells with emulsions therein toproduce product at a rate of about at least 1 fps.

In particular embodiments, it is believed that certain systemscontemplated by the present invention may be configured to produce overabout 200 linear feet of elongate consumable meat product in less thanabout 1 minute. Such an automated process may be employed withoutrequiring direct manual labor to form or remove the products from thetube 15 and/or wrappable member 5, and, hence, may be particularlysuitable for mass-production environments. In other particularembodiments, the system 10 may be configured with a plurality ofproduction lines running at a rate of about 3 fps or more to produceabout 5,000-15,000 lbs/hour of the same or different food products usingthe forming tubes contemplated by the present invention. In certainembodiments, the system 10 is configured to yield at least about 900lbs/hour and, in other embodiments, the system may yield about at least10,000 lbs/hour of product 30P.

In certain embodiments, the tubes 15 can be configured with about aone-inch outer diameter and/or about a 0.75 inch inner diameter. Thus,in certain embodiments, such as those using five parallel lines as shownin FIGS. 5A, 5C, 6A, 6B, and 6C, and a flow rate through the tubes ofabout 3 fps of emulsion, which may be heated by independently controlledgenerators (21A₁-21A₅ as shown in FIG. 5A) and wave guides andapplicators in 316 SST (and/or aluminum) (not shown) with the tubes 15formed of TEFLON with plastic welded TriClamp connections, about10-13,500 lbs/hour of product 30P maybe produced.

In certain embodiments, the system 10 is configured to yield elongatedproduct 30 p that can be configured as a continuous length of producthaving a length of at least about 2 inches. In certain embodiments, thecontinuous length of product 30 p can be at least about 1 foot. Incertain embodiments, the length may be about 20-25 feet. In otherembodiments, the length of a continuous product may be up to about 50feet, or even longer (which may be subsequently divided into desiredlengths). The product may be cut into desired sizes as it is held in thetube (with the tube formed with cutting apertures), as it leaves thetube, or downstream thereof.

FIG. 8A illustrates that each forming tube 15 may be in fluidcommunication with its own supply source 50 s and associated valves 50 vthat control the flow rate of the emulsion that is pumped into theingress portion of the respective forming tube 15. The wrappable memberis not illustrated in FIG. 8C and only in a single line in FIG. 8A forclarity. The valves and pumps may be controlled by a common systemcontroller 60 or separate controllers (not shown). FIG. 8A alsoillustrates that the tubes 15 may be configured with a non-metallicregion 15N having a length L₁ that terminates into a region that ismetallic and has a length L₂. The product 30 p exits from the metallicportion after a suitable distance. Metallic lengths may be configured inadvance of and into the thermal source in the processing region 20 aswell. The conveyor forming the wrappable member 5 may be configured andsized to have its travel path held within the enclosure proximate eachtube 15, or, as shown, to direct a portion of the belt to travel in itsreturn via an externally located travel path.

FIG. 8B illustrates that the system 10 may include a primary hopper 50 sthat feeds a plurality of sub-hoppers 50 sub, each associated with oneor more of the forming tubes 15. Accordingly, the system may includeassociated primary and secondary valves 50 v ₁, 50 v ₂, respectively,along each path 15 p. One or more pumps or flow sources can be disposedin the flow paths 15 p as desired to provide the entry pressure and flowinto the respective wrappable members 5 and/or tubes 15 (not shown).FIG. 8B also illustrates that the product 30 p can be released from thewrappable member (such as shown as feature 5 in FIG. 2B) and dischargedfrom the respective forming tube 15 at the exit of the enclosedprocessing region 20 (or prior to their exit therefrom). The wrappablemembers 5 may be nested as shown, with one extending a further verticaland horizontal distance than the other, or configured to be locatedsymmetrically spaced and substantially constant in size line to line,about a respective forming tube 15 (not shown).

FIG. 8C illustrates that the supply source 50 s for a plurality offorming tubes 15 can be a primary hopper. As such, a distributionmanifold 50 m and associated valving 50 v can be used to selectivelydirect the flow and emulsion quantities to the desired travel paths 15 pand into the respective members 5 (FIG. 2B) and tubes 15. Again, thevalves 50 v and distribution in the manifold 50 m can be controlled by acentral controller 60. The valves can be remotely controlled andactuated (pneumatically, hydraulically, or electrically). The system 10can include one or more pumps to provide the input pressure and flowrate of the emulsion into the ingress portion of the wrappable membersproximate the respective tubes 15.

As shown in FIG. 11A, the system 10′ can include a plurality of separatetraveling endless wrappable members 5, a respective one for eachdifferent production line. As before, they can be configured to travelthrough a common processing region 20. Thus, each production line caninclude a respective endless wrappable member 5 and forming tube 15 withassociated travel paths 15 p. As such, the mold shells 15 m for eachproduction line can be directed to travel through the processing regionconcurrently (using a processing region configured to surround aplurality of production lines, with a shared heating, holding and/orcooling region). Each line may be operated to yield the same product inthe same or different shapes or sizes, or different products. The system10′ may include a central controller 60 that directs the operation of aplurality of different energy sources. The controller 60 can adjust theenergy generated depending on the type of product traveling in theprocessing region (such as the size of the forming tube 15 (volume), thetype of emulsion mixture in the forming tube 15, the rate of speed ofthe wrappable member 5, and the like). The energy sources 21a may be ofthe same type and operated to maintain a homogenous or constant energyor temperature region in the processing region. Alternatively, selectedones of the energy sources 21 a may be operated to produce local “hot”or “cold” spots or a graduated heating or cooling treatment zones asdesired. FIG. 11A also illustrates that the temperature of the productcan be raised from a first starting temperature T₁ to a second cookedtemperature, T₂ that is at least about double the starting temperaturemeasured in degrees Fahrenheit. The food emulsion may start at atemperature of about 50 degrees Fahrenheit and be processed to reach atemperature of about 158 degrees Fahrenheit.

FIG. 1 1A illustrates that the lines may be oriented one above the otherand directed to flow in a substantially horizontal throughputconfiguration, with the wrappable members 5 moving in horizontal forwardand rearward directions for a major portion of the length of the travelpath 15 p ₁, 15 p ₂. FIG. 11B illustrates an alternative example of twolines used to move the product through the processing region. FIG. 11Billustrates that the lines may be configured in side-by-side alignmentand oriented to move in a vertical throughput configuration, with thewrappable members 5 traveling in a vertically upward or downwarddirection for a major portion of the length of the travel path 15 p ₁,15 p ₂.

The systems 10 may be configured to cook, freeze, smoke, cure, pickle,partially dehydrate, or otherwise process the food as it moves throughthe processing region(s) 20.

The foregoing is illustrative of the present invention and is not to beconstrued as limiting thereof. Although a few exemplary embodiments ofthis invention have been described, those skilled in the art willreadily appreciate that many modifications are possible in the exemplaryembodiments without materially departing from the novel teachings andadvantages of this invention. Accordingly, all such modifications areintended to be included within the scope of this invention as defined inthe claims. In the claims, means-plus-function clauses, where used, areintended to cover the structures described herein as performing therecited function and not only structural equivalents but also equivalentstructures. Therefore, it is to be understood that the foregoing isillustrative of the present invention and is not to be construed aslimited to the specific embodiments disclosed, and that modifications tothe disclosed embodiments, as well as other embodiments, are intended tobe included within the scope of the appended claims. The invention isdefined by the following claims, with equivalents of the claims to beincluded therein.

1. A food production system, comprising: at least one flexible wrappablemember having opposing first and second lateral edges and a primarysurface, the flexible wrappable member arranged to extend axially in apredetermined endless travel path, wherein, the first and second lateraledges are configured such that, in operation, they have a first spacedapart configuration and a second configuration, with the lateral edgesbeing positioned closer to one another in the second configuration, andwherein, when in the second configuration, the at least one flexiblewrappable member defines a perimeter with an internal cavity gap space;at least one forming tube having sufficient structural rigidity todefine a preformed cavity space with a predetermined configuration, theat least one forming tube having opposing ingress and egress portions; aflowable food emulsion source that is configured to introduce emulsiononto the wrappable member proximate to the at least one forming tube sothat the emulsion resides in the internal cavity space of the secondconfiguration; a transport system that is configured to move thewrappable member so that the wrappable member substantially continuouslytravels, in serial order, to a first location that is in fluidcommunication with the food emulsion source, through said at least oneforming tube, and back to the first location; and a processing regionhaving a thermal energy source operably associated with thepredetermined travel path so that, in operation, the processing regionexposes the emulsion in the wrappable member in the forming tube to apredetermined thermal processing condition as the wrappable membertravels along a portion of the endless travel path to convert emulsionheld in the at least one forming tube to a non-flowable food producthaving substantially the molded shape of the forming tube cavity.
 2. Asystem according to claim 1, wherein, in operation, the flowable foodemulsion source is configured to substantially continuously introduceemulsion onto the wrappable member at the first location.
 3. A systemaccording to claim 1, wherein, in operation, the flowable food emulsionsource is configured to introduce the emulsion at desired intervals ontothe wrappable member at the first location.
 4. A system according toclaim 1, wherein the second configuration perimeter is a closedperimeter that encases the internal cavity space and holds the flowableemulsion therein downstream of the first location and in the formingtube.
 5. A system according to claim 4, wherein, in the secondconfiguration, one of the respective lateral edge portions overlaps theother.
 6. A system according to claim 4, wherein, in the secondconfiguration, the lateral edges abut to define a seam region.
 7. Asystem according to claim 1, further comprising wrapping means disposedupstream of the at least one forming tube, the wrapping means configuredto wrap the wrappable member into a desired configuration.
 8. A systemaccording to claim 1, wherein the at least one wrappable member is asingle member having having a width that is sufficient to define aclosed perimeter with the opposing lateral edges positioned proximate toeach other to define an encased internal cavity gap space.
 9. A systemaccording to claim 8, wherein the wrappable member has a substantiallyplanar configuration during a major portion of the predetermined travelpath, and wherein the second configuration is substantially cylindricalwith the opposing lateral edge portions moved both upward and inward sothat the lateral edge portions reside proximate to each other.
 10. Asystem according to claim 9, wherein the wrappable member has a thirdemulsion filled configuration that is different from the secondconfiguration, and wherein, in operation, the third configuration isgenerated when the emulsion is held in the wrappable member in theforming tube so that the flexible members expand outwardly to contactand take the shape of the forming tube.
 11. A system according to claim1, wherein the at least one wrappable member has a primary surface thathas a pre-formed concave configuration.
 12. A system according to claim1, wherein the at least one flexible cover member is a plurality ofcover members, and wherein the transport system is configured to movethe plurality of cover members in concert and direct them to meetproximate the forming tube to define the second configuration perimeterwith the internal cavity gap space.
 13. A system according to claim 12,wherein the second configuration perimeter shape of the wrappable memberis held spaced apart from the forming tube, wherein the flexiblewrapping members have a third configuration, the third configurationhaving a larger cross-sectional area than the second configuration, andwherein, in operation, the third configuration is an outwardly expandedconfiguration wherein the flexible wrappable member expands outwardly tocontact and take substantially the shape of the forming tube.
 14. Asystem according to claim 1, wherein the transport system and at leastone wrappable cover member are configured so that the wrappable memberlateral edge portions releasably attach at a first location and thenautomatically separate at a second downstream location to release thenon-flowable food product.
 15. A system according to claim 1, whereinthe transport system is arranged to move the at least one wrappablemember in a substantially vertical orientation along a major portion ofthe predetermined travel path.
 16. A system according to claim 1,wherein the transport system is arranged to move the at least onewrappable member in a substantially horizontal orientation along a majorportion of the predetermined travel path.
 17. A system according toclaim 1, wherein the system defines a food travel path that is a subsetof the wrappable member endless travel path and extends between spacedapart first and second locations along the endless travel path, andwherein the at least one wrappable member is configured to seriallytravel so that: (a) the opposing lateral edge portions come together todefine a closed perimeter with a gap space internal cavity at the firstlocation, (b) the opposing lateral edge portions remain together withthe closed perimeter intact through the forming tube encasing theemulsion, (c) the opposing lateral edge portions separate at a secondlocation downstream of the first location to define an open perimeterexposing the non-flowable food product, and then (d) the spaced apartlateral edge portions travel for a second portion of the endless travelpath to return to the first location, the first location of the foodtravel path being proximate the food emulsion source.
 18. A systemaccording to claim 1, further comprising: a second flexible wrappablemember having opposing first and second lateral edges and a primarysurface, the flexible wrappable member arranged to extend axially in apredetermined second endless travel path that is spaced apart from thefirst endless travel path of the first wrappable member, wherein, inoperation, the first and second lateral edges thereof are configured tohave a first spaced apart configuration and a second configuration withthe lateral edges positioned closer one another in the secondconfiguration, and wherein, when in the second configuration, the atleast one flexible wrappable member defines a perimeter with an internalcavity gap space; a second forming tube having sufficient structuralrigidity to define a preformed cavity space with a predeterminedconfiguration, the second forming tube having opposing ingress andegress portions; a second flowable food emulsion source that isconfigured to introduce emulsion onto the second wrappable memberproximate to the second forming tube so that the emulsion resides in theinternal cavity space of the second wrappable member in the secondconfiguration; a second transport system that is configured to move thesecond wrappable member so that the second wrappable membersubstantially continuously travels, in serial order, to a first locationthat is in fluid communication with the second food emulsion source,through said second at least one forming tube, and back to the firstlocation; and wherein the second predetermined travel path extendsthrough the processing region so that, in operation, the processingregion concurrently exposes the emulsion in the first and secondwrappable members in the respective forming tubes to a predeterminedthermal processing condition to convert the emulsion to a non-flowablefood product having substantially the molded shape of the forming tubecavity.
 19. A system according to claim 1, wherein the primary surfaceof the wrappable member comprises raised and/or deformed regions formedthereon, the regions corresponding to surface indicia or texture patternthat applied to the outer surface of the food product.
 20. A systemaccording to claim 19, wherein the surface indicia pattern isalphanumeric.
 21. A system according to claim 19, wherein the surfaceindicia pattern is in the shape of a logo design.
 22. A system accordingto claim 1, wherein the forming tube is configured with a non-circularcross-sectional profile.
 23. A system according to claim 1, wherein theprocessing region thermal source comprises an oven for heating theemulsion in the forming tubes for predetermined times and temperaturesas the emulsion travels enclosed in the wrappable member therein.
 24. Asystem according to claim 23, wherein the oven is configured to generatesufficient energy and the respective shell residence time therein issuch that the internal temperature of the shell enclosed emulsion risesto at least about 150 degrees F.
 25. A system according to claim 23,wherein the processing region further comprises a cooler that cools theemulsion in the shells for a predetermined time.
 26. A system accordingto claim 1, wherein the processing region thermal source comprises amicrowave energy source that is configured to direct microwave energy atthe emulsion for a predetermined time and energy level.
 27. A systemaccording to claim 1, wherein the processing region thermal sourcecomprises an RF energy source that is configured to direct RF energy atthe emulsion for a predetermined time and energy level.
 28. A systemaccording to claim 1, wherein the wrappable member is configured toadvance along the endless path at about least about 1 fps.
 29. A systemaccording to claim 1, wherein the emulsion source is configured tointroduce the flowable emulsion with sufficient pressure to cause theemulsion to substantially fill the volume of the cavity of the secondconfiguration of the wrappable member and/or the at least one formingtube.
 30. A system according to claim 1, wherein the flowable emulsionis formulated and the forming tube is configured to produce a shapedburger product.
 31. A system according to claim 1, wherein the flowableemulsion comprises at least one meat, meat analog, or meat derivative.32. A system according to claim 31, wherein the emulsion comprises atleast one of pork, beef, veal, and/or poultry.
 33. A system according toclaim 32, wherein the emulsion comprises ground pork, ground beef andground veal.
 34. A system according to claim 1, wherein the emulsion isconfigured with ingredients to provide hot dogs as the resultant foodproduct.
 35. A system according to claim 1, wherein the emulsion isconfigured with ingredients to provide sausages as the resultant foodproduct.
 36. A system according to claim 1, wherein, in operation, anouter layer of simulated skin having an increased density relative tothe underlying food material is formed onto the food product based onprocessing conditions generated in the processing region.
 37. A systemaccording to claim 36, wherein the skin layer is generated by at leastone of the residence time of the at least one forming tube in theprocessing region, the type of processing energy employed in theprocessing region, the energy level generated in the processing region,and the temperature that the outer region of the emulsion is exposed towhile in the wrappable member in the forming tube.
 38. An apparatus forproducing food products, comprising: means for moving at least oneflexible cover member having a predetermined length with primary surfaceand opposing lateral edge portions along a predetermined travel path;means for introducing a flowable food emulsion onto the primary surfaceof the flexible cover member; means for wrapping the at least oneflexible cover member about the food emulsion during the moving step;means for providing at least one forming tube having sufficientstructural rigidity to be substantially non-deformable and having apreformed internal cavity space of predetermined size and shape; andmeans for exposing the wrapped emulsion to predetermined processingconditions that convert the flowable emulsion to a non-flowable foodproduct having substantially the molded shape of the forming tube as thewrapped emulsion advances through the at least one forming tube.
 39. Anapparatus according to claim 38, wherein the predetermined travel pathis an endless travel path.
 40. An apparatus according to claim 39,wherein the cover member is substantially continuously moved along theendless travel path.
 41. An apparatus according to claim 38, wherein theat least one flexible cover member is a single cover member having awidth that is sufficient to define a perimeter with the opposing lateraledges positioned proximate to each other and an internal cavity gapspace.
 42. An apparatus according to claim 38, wherein the at least oneflexible cover member is a plurality of cover members that move inconcert and meet proximate the forming tube to define a perimeter withan associated internal cavity gap space, and wherein the step ofwrapping comprises directing the plurality of cover members to meet todefine a perimeter with opposing lateral edges of each cover memberdisposed proximate to the opposing lateral edge of a different covermember.
 43. An apparatus according to claim 3 8, wherein the emulsion ocomprises at least one type of meat, meat analog, or meat derivative.44. An apparatus according to claim 3 8, wherein the emulsion comprisesat least one of pork, beef, lamb, veal, and poultry and/or analogs orderivatives thereof.